I would be curious what you see inside a failed unit. Is the internal failure easy to view? Bob K. -----Original Message----- From: TechNet [mailto:[log in to unmask]] On Behalf Of Bev Christian Sent: Thursday, July 28, 2016 11:45 AM To: [log in to unmask] Subject: Re: [TN] Prepping TO-5 can style Relay... Steve, Do they have PROOF that bending the leads cause damage? Bev -----Original Message----- From: TechNet [mailto:[log in to unmask]] On Behalf Of Steve Gregory Sent: Thursday, July 28, 2016 11:12 AM To: [log in to unmask] Subject: [TN] Prepping TO-5 can style Relay... Hi All, We're building a board for a customer that uses a 8-lead TO-5 style relay. The footprint on the board requires that the leads are spread out to a larger diameter circle than what diameter is when they come out of the body at the bottom of the relay. Here's the information for one of the relays, there are three others that are the same style: http://www.digikey.com/product-search/en?lang=en&site=us&WT.z_cid=ref_findch ips_standard&mpart=PRMAC-26X So we have a Simonds CLP274 lead processor with a die that matches the footprint on the PCB: http://stevezeva.homestead.com/Simonds_CLP274.jpg We insert the part which spreads the leads out, then step on the pedal and a guillotine style blade shears the leads off. I've used the prep unit many, many time before at previous employers without issues. The customer is saying that prepping the leads in this unit is damaging the relay. So now we are to pot the leads before prepping them with a 2-part epoxy using a tooling fixture as a mold for the epoxy, and the potted relay looks like this: http://stevezeva.homestead.com/Potted_Relay.jpg Has anybody ever heard of this Simonds unit damaging relays like this? Has anybody had to add potting to a relay like this? I can understand wanting to keep the leads coming straight out of the bottom of the body before making the bend to match the footprint on the board, but I think I can use a Bivar permanent spacer and slip it over the lead and accomplish the same thing. Something like this: https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwi qk8zCt5bOAhWJ1IMKHebaCR8QFggxMAE&url=http%3A%2F%2Fwww.bivar.com%2Fportals%2F 0%2Fproducts%2F616-070.pdf&usg=AFQjCNESVvvX6qOo_-0T94sAYNLP8AJ21Q&cad=rja Or even a nylon washer that matches the diameter of the lead pattern (.200") coming out of the bottom of the relay. Potting this relay is going to be very time consuming and there's going to be a risk of getting the epoxy on the leads that will ruin the solderability of the part. I'm just trying to understand if it is truly the Simonds prep unit causing the damage, and if this really is, and easier way other than potting them to accomplish the same thing. Thanks all! Steve Gregory -- This email and any attachments are only for use by the intended recipient(s) and may contain legally privileged, confidential, proprietary or otherwise private information. Any unauthorized use, reproduction, dissemination, distribution or other disclosure of the contents of this e-mail or its attachments is strictly prohibited. If you have received this email in error, please notify the sender immediately and delete the original.